Starch-based padding for roll stock and padded mailers and method of making the same

ABSTRACT

Padded materials and corresponding systems and methods for forming the same are provided herein. A padded material comprises a first web of paper-based material defining a first and a second surface, and a second web of paper-based material defining a first and a second surface. A first layer of heat seal coating is disposed on the second surface of the first web, and a second layer of heat seal coating is disposed on the second surface of the second web. A starch-based padding is sandwiched between the first web and the second web such that the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web. The padded material may be formed into a roll stock that is used in an automated packaging machine, such as an automated mailer formation device.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Application No.63/513,491, entitled “Starch-Based Padding for Roll Stock and PaddedMailers and Method of Making the Same”, filed Jul. 13, 2023, and U.S.Provisional Application No. 63/389,953, entitled “Starch-Based Paddingfor Roll Stock and Padded Mailers”, filed Jul. 18, 2022; the contents ofeach being hereby incorporated by reference in its entirety.

FIELD

Embodiments relate generally to starch-based padding in roll stock formand for padded mailers, along with methods and systems for making thesame.

BACKGROUND

There is an increased demand for delivery of items, such as directly toan end user's home or office. Further, increased efficiency in thelogistics of performing delivery has also driven up deliverycapabilities. However, there is also a desire to provide for delivery inpackaging that both prevents damage to the items being delivered and isenvironmentally friendly, such as for padded material and/or paddedmailers.

Padded mailers are one such form of a packaging option. Some examplepadded mailers include two panels that attach on at least three sides tocreate a pocket for holding an item (e.g., document, blister pack,batteries, retail products, etc.). Some padded mailers can be formedaround the item for shipping and delivery, such as using an automatedmailer formation device. Other example padded mailers are formed with anopen pocket (such as by attaching three sides and leaving the fourthside open). Once such a padded mailer is formed, the item can be placedinside and the fourth side can be sealed—often by folding over a flap onone of the panels and sealing it to the other panel. Additionalfeatures, such as tear strips or pull-strip adhesive can be provided onthe padded mailer for ease of packaging and/or opening. Some paddedmailers form the paneling or other portions from plastic or othermaterial that is non-recyclable.

Padded mailers, notably, also include padding, such as within internalpouches in one or more of the panels to provide cushioning andprotection for the item inside the pocket. Unfortunately, many paddedmailers are formed using plastic for the padding, such as via air cellsor other technology. Such plastic, as noted above, however is typicallynon-recyclable.

As such, there is a desire to form more easily recyclable paddedmaterial and/or padded mailers. Additionally, there is a desire forimprovements in the formation of padded mailers, such as allowing forhigher production speeds and utilization of less material.

BRIEF SUMMARY

Some embodiments of the present invention form a recyclable paddedmaterial, such as may be used to form a padded mailer. For example, thepadded material may be formed into a roll for shipping and/or conversionto a desired product (such as a padding square, a padded mailer, etc.).In some embodiments, a starch-based padding is employed, where thestarch-based padding has increased resilience over typical starchparticles, but is also recyclable. The starch-based padding may beformed, such as via an extruder, and applied onto a web (e.g.,paper-based web). A fluid, such as water, may be used to help adhere (orpartially-adhere) the starch-based padding to the web. A second web maybe brought into contact with the starch-based padding on the first webto form the padded material. Notably, the padded material may becurbside recyclable, biodegradable, and compostable.

In some embodiments, the starch-based padding may be configured as aplurality of starch-based particles. In some embodiments, thestarch-based particles may be placed in a pattern on the first web. Thespecific pattern may create desired spacing between one or morestarch-based particles. The specific pattern may provide beneficialproperties, such as increased padding protection, reduced materialusage, easier assembly or formation of products (e.g., a padded mailer),among other things.

In some embodiments, the starch-based particles may be transferred froman extruder to the first web using an apparatus. The apparatus maycomprise at least a hopper and a vacuum-based placement devices, such asa wheel, belt, or other device. The hopper may store the starch-basedparticles after formation, and prior to adhesion, while, for example,the vacuum wheel may engage the starch-based particles, for example, viavacuum suction, to transfer the starch-based particles from the hopperto the first web.

In some embodiments, the starch-based padding may be crushed to furtherincrease the desired padding effect (e.g., resilience) and reducethickness of the final laminate. The crushing may occur simultaneouslyor near simultaneously with application of the starch-based padding ontothe first web. Additionally or alternatively, the crushing may occurafter the second web has been brought in contact with the starch-basedpadding and the first web.

In some embodiments, a heat seal coating may be applied to various sidesof the first and/or second web. The heat seal coating may help information of the padded material and/or formation of later products ofthe padded material, such as a padded mailer. In particular, forexample, a heat seal coating layer being positioned within the internalpocket that includes the starch-based padding may enable cutting andsealing to occur at any point along the padded material—which enablesthe padded material to be utilized with automated packaging machinesthat form the padded material into a package (e.g., a padded mailer)around an item. Notably, such automated packaging machines often utilizevariable cutting and/or sealing positions along the padded material and,thus, having the heat seal coating layer extend within the internalpocket enables the starch-based padding therein to be contained nomatter where along the padded material the cut and seal occurs.

In some embodiments, the padded material may be formed in a variety ofways. For example, two webs of the padded material may be broughttogether to form the padded mailer (e.g., with various mailer features).Such a padded mailer may be hand packed with an item, for example. Asanother example, the padded material may pass through an automatedmailer formation device where the padded material may be folded aroundthe item to be packed. Thereafter, various features of the padded mailermay be formed thereon.

In an example embodiment, a packaging material for use in an automatedpackaging machine is provided. The packaging material comprises a firstweb of paper-based material defining a first surface and a secondsurface opposite the first surface, and a first layer of heat sealcoating disposed on the second surface of the first web. The packagingmaterial further comprises a second web of paper-based material defininga second surface opposite the first surface, and a second layer of heatseal coating disposed on the second surface of the second web. Thpackaging material further comprises a starch-based padding sandwichedbetween the first web and the second web, more particularly thestarch-based padding is positioned between the first surface of thefirst web and the second layer of heat seal coating disposed on thesecond surface of the second web.

In some embodiments, the starch-based padding may cover between about20% to about 40% of the first surface of the first web. In someembodiments, the starch-based padding may be precrushed defining a finaldensity between about 1.5 lbs/ft³ to about 2.25 lbs/ft³ after thestarch-based padding is precrushed. In some embodiments, thestarch-based padding may comprise lignin. In some embodiments, the firstsurface of the first web may be moistened prior to contact with thestarch-based padding. In some embodiments, the second layer of heat sealcoating may be moistened prior to contact with the starch-based padding.In some embodiments, the starch-based padding may comprise starch, aplasticizer and a foaming aid.

In some embodiments, the starch-based padding may be a plurality ofstarch-based particles. In some embodiments, each of the plurality ofstarch-based particles may define a particle diameter between about 0.2in to about 0.4 in. In some embodiments, each of the plurality ofstarch-based particles may define a particle thickness between about 0.1in to about 0.25 in. In some embodiments, the starch-based padding maybe a sheet.

In another example embodiment, a method of forming a packaging materialfor use in an automated packaging machine is provided. The methodcomprises providing a first web of paper-based material defining a firstsurface and a second surface, and applying a first layer of heat sealcoating to the second surface of the first web. The method furthercomprises providing a second web of paper-based material defining afirst surface and a second surface, and applying a second layer of heatseal coating to the second surface of the second web. The method furthercomprises applying a starch-based padding onto the first surface of thefirst web. The method further comprises causing the first web and thesecond web to come together such that the starch-based padding issandwiched between the first web and the second web. The starch-basedpadding being positioned between the first surface of the first web andthe second layer of heat seal coating disposed on the second surface ofthe second web.

In some embodiments, the starch-based padding may be a plurality ofstarch-based particles. In some embodiments, the method may furthercomprise transferring the plurality of starch based particles from ahopper to a vacuum wheel, the vacuum wheel comprising a plurality ofopenings in a determined pattern. In some embodiments, the plurality ofstarch-based particles are secured within the plurality of openings viavacuum suction.

In yet another example embodiment, a mailer formed from a paddedmaterial is provided. The padded material comprises a first web ofpaper-based material defining a first surface and a second surfaceopposite the first surface, and a first layer of heat seal coatingdisposed on the second surface of the first web. The packaging materialfurther comprises a second web of paper-based material defining a secondsurface opposite the first surface, and a second layer of heat sealcoating disposed on the second surface of the second web. Th packagingmaterial further comprises a starch-based padding sandwiched between thefirst web and the second web, more particularly the starch-based paddingis positioned between the first surface of the first web and the secondweb.

In some embodiments, the starch-based padding may cover between about20% to about 40% of the first surface of the first web. In someembodiments, the starch-based padding may define a final density ofabout 1.5 lbs/ft³ to about 2.25 lbs/ft³ after the starch-based paddingis precrushed. In some embodiments, the starch-based padding maycomprise lignin. In some embodiments, the first surface of the first webmay be moistened prior to contact with the starch-based padding. In someembodiments, the second layer of heat seal coating may be moistenedprior to contact with the starch-based padding. In some embodiments, thestarch-based padding may comprise starch, a plasticizer, and a foamingaid.

In some embodiments, the starch-based padding may be a plurality ofstarch-based particles. In some embodiments, each of the plurality ofstarch-based particles define a particle diameter between about 0.2 into about 0.25 in. In some embodiments, each of the plurality ofstarch-based particles define a particle thickness between about 0.1 into about 0.25 in. In some embodiments, the starch-based padding may be astarch-based sheet.

In yet another example embodiment, a mailer produced by a process isprovided. The process comprises providing a first web of paper-basedmaterial defining a first surface and a second surface, and applying afirst layer of heat seal coating to the second surface of the first web.The process further comprises providing a second web of paper-basedmaterial defining a first surface and a second surface, and applying asecond layer of heat seal coating to the second surface of the secondweb. The process further comprises applying a starch-based padding ontothe first surface of the first web. The process further comprisescausing the first web and the second web to come together such that thestarch-based padding is sandwiched between the first web and the secondweb. The starch-based padding being positioned between the first surfaceof the first web and the second layer of heat seal coating disposed onthe second surface of the second web.

In yet another example embodiment, a system for positioning starch-basedpadding on a paper-based material web for use in a padded packagingmaterial is provided. The system comprises a hopper for receiving aplurality of starch-based particles, and an infeed attached to an upperportion of the hopper. The infeed supplies the hopper with the pluralityof starch-based particles. The system further comprises a vacuum wheelextending along a width of the hopper. The vacuum wheel is configured torotate in a first direction to transfer the plurality of starch-basedparticles from the hopper to a first web of paper-based material. Thesystem further comprises an acceleration device positioned within thehopper. The acceleration device spans the width of the hopper and isconfigured to rotate in a second direction, opposite the firstdirection. The rotation of the acceleration device causes the pluralityof starch-based particles to accelerate so as to travel at a particlerotational speed that matches a vacuum wheel rotational speed forengagement of the plurality of the starch-based particles with thevacuum wheel.

In some embodiments, the acceleration device may be a brush. In someembodiments, the system may further comprise a level control deviceconfigured to rotate in the second direction. Rotation of the levelcontrol device causes the plurality of starch-based particles todistribute along the width of the hopper. In some embodiments, the levelcontrol device may comprise a plurality of fins each extending along thewidth of the hopper. In some embodiments, the level control device maycomprise a plurality of bristles positioned on an end of each of theplurality of fins. In some embodiments, the vacuum wheel may comprise aplurality of openings supplied with vacuum suctions. The vacuum suctionmay secure each of the plurality of starch-based particles in acorresponding each of the plurality of openings during rotation from thehopper to the first web.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 shows an example roll of padded material, in accordance with someembodiments discussed herein;

FIG. 2 illustrates an example cross-section of the padded material shownin FIG. 1 , in accordance with some embodiments discussed herein;

FIG. 3 shows a portion of the roll of padded material shown in FIG. 1with a top web removed to show starch-based particles positioned on thebottom web, in accordance with some embodiments discussed herein;

FIG. 4A shows an example schematic view of a portion of the paddedmaterial shown in FIG. 3 illustrating an example pattern of starch-basedparticles on the web, in accordance with some embodiments discussedherein;

FIG. 4B shows a close-up view of a portion of the padded material shownin FIG. 3 illustrating another example pattern of starch-based particleson the web, in accordance with some embodiments discussed herein;

FIG. 5 shows a schematic representation of an example system for formingpadded material, in accordance with some embodiments discussed herein;

FIG. 6A illustrates a schematic representation of the example system forforming padded material, in accordance with some embodiments discussedherein;

FIG. 6B illustrates a side view, of an example apparatus for positioningstarch-based padding, in accordance with some embodiments discussedherein;

FIG. 6C shows a perspective view of a portion of the example apparatusshown in FIG. 6B, in accordance with some embodiments discussed herein;

FIG. 6D shows a side view of a portion of the example apparatus shown inFIG. 6B, in accordance with some embodiments discussed herein;

FIG. 6E shows a side view of a portion of the example apparatus shown inFIG. 6B, in accordance with some embodiments discussed herein;

FIG. 6F illustrates a close-up perspective view of a surface of thevacuum wheel of the example apparatus shown in FIG. 6B, in accordancewith some embodiments discussed herein;

FIG. 7A illustrates a close up view of an example padded materialillustrating a starch based sheet used in the padding material, inaccordance with some embodiments discussed herein;

FIG. 7B illustrates a cross sectional view of the example paddedmaterial shown in FIG. 7A, in accordance with some embodiments discussedherein;

FIG. 8A illustrates a schematic representation of an example system forforming padded material illustrated in FIG. 7A, in accordance with someembodiments discussed herein;

FIG. 8B shows a schematic representation of a portion of the examplesystem illustrated in FIG. 8A, in accordance with some embodimentsdiscussed herein;

FIG. 9 illustrates a schematic representation of an example system usingan automated padded mailer formation device for forming a padded mailerfrom the padded material, in accordance with some embodiments discussedherein;

FIG. 10A illustrates a top view of an example padded mailer formed fromthe example automated padded mailer formation device shown in FIG. 9 ,in accordance with some embodiments discussed herein;

FIG. 10B illustrates a cross-sectional view of a portion of the examplepadded mailer of FIG. 10A taken within circle B, in accordance with someembodiments discussed herein;

FIG. 11A shows a top view of an example padded mailer, in accordancewith some embodiments discussed herein;

FIG. 11B shows a cross-sectional view of the example padded mailer shownin FIG. 11A taken along line B-B, with an item shown packed therein, inaccordance with some embodiments discussed herein;

FIG. 11C shows a cross-sectional view of the example padded mailer shownin FIG. 11A taken along line C-C, with an item shown packed therein, inaccordance with some embodiments discussed herein;

FIG. 12A shows an example padded mailer, in accordance with someembodiments discussed herein;

FIG. 12B is a cross-sectional view of the padded mailer shown in FIG.12A taken along line A-A, with an item shown packed therein, inaccordance with some embodiments discussed herein;

FIG. 13 illustrates a schematic representation of an example systemusing a hand pack mailer formation device for forming a padded mailerfrom the padded material, in accordance with some embodiments discussedherein;

FIG. 14 illustrates a flowchart for forming a padded mailer from apadded material, in accordance with some embodiments discussed herein;and

FIG. 15 illustrates a flowchart for forming a padded mailer from apadded material, in accordance with some embodiments discussed herein.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafterwith reference to the accompanying drawings, in which some, but not allexample embodiments are shown. Indeed, the examples described andpictured herein should not be construed as being limiting as to thescope, applicability or configuration of the present disclosure. Rather,these example embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Like reference numerals refer tolike elements throughout.

FIG. 1 shows an example roll 10 of padded material 20. The paddedmaterial 20, such as formed according to various embodiments describedherein, is rolled about a center spool 12. As detailed herein, the rollof padded material 20 may be easily shipped and/or transported andconverted into various products, such as padding, padded mailers, etc.

FIG. 2 illustrates a schematic view of a cross-section of the paddedmaterial 20. Notably, the padded material is formed of a first web 22and a second web 24 with padding (such as starch-based particles 40)positioned therebetween. In some embodiments, other padding material maybe used in addition to or in alternative to the starch-based particles40, for example, a starch-based sheet shown in FIG. 7A.

Each of the first web 22 and the second web 24 define a first surface 22a, 24 a and a second surface 22 b, 24 b opposite the first surface 22 a,24 a, respectively. In regards to the first web 22, in some embodiments,the first surface 22 a may be inward facing (e.g., towards thestarch-based particles 40), and the second surface 22 b may be outwardfacing. In contrast, in regards, to the second web 24, the first surface24 a may be outward facing, while the second surface 24 b may be inwardfacing (e.g., towards the starch-based particles 40).

In the illustrated embodiment, a first layer of heat seal coating 32 isapplied to the second surface 22 b of the first web 22 and a secondlayer of heat seal coating 34 is applied to the second surface 24 b ofthe second web 24. In some embodiments, the first layer of heat sealcoating 32 may face a corresponding second surface of a second first web22 of another padded material such that the first layers of heat sealcoating 32 would be adjacent and may be utilized to adhere or otherwiseconnect the two padded material layers (see e.g., 552 of FIG. 10B andthe corresponding description). In some embodiments, the second heatseal coating layer 34 may interact with the starch-based particles 40,and in some embodiments form a heat seal between the second heat sealcoating layer 34 and the starch-based particles 40, and/or between thesecond heat seal coating layer 34 and the first surface 22 a of thefirst web 22 (e.g., if the padded material 20 is cut and sealed withinan automated mailer formation device, such as described herein).

In some embodiments, the heat seal coating (e.g., the first layer ofheat seal coating 32 and/or the second layer of heat seal coating 34)may be recyclable. In some embodiments, the heat seal coating may beapplied to cover between 1%-100% of the surface of the first web or thesecond web. In some embodiments, the heat seal coating may be applied tocover between 95%-100% of the surface of the first web or second web,such as along the second surface 22 b of the first web 22 for use in anautomated packaging machine that may apply a cut and/or seal actionanywhere along the length of the padded material.

In some embodiments, the heat seal coating may be applied to coverbetween 1%-25% of the surface of the first web and/or the second web,with the coverage area being localized to specific regions of the webwhere the machine direction and cross direction seals are to be formedfor converting equipment that has control over location of heat seals.In this regard, in some embodiments, the positioning of the heat sealcoating may be specific to reduce usage thereof. For example, the heatseal coating may be applied at predetermined intervals, such as every 2in., every 6 in., etc.

In some embodiments, the heat seal coating comprises thermoplasticcoatings or adhesives that enable sealing of various surfaces when acombination of heat and pressure is applied. In some embodiments, theheat seal coating may have a recyclable formulation, which may includeone or more of: PVOH, PVAc, and/or thermoplastic starches. In someembodiments, the heat seal coating includes an anti-blocking agenteither in the coating formulation or as a separate coating layer, suchas wax.

In some embodiments, the heat seal coating may be added to the secondweb 24 on the second surface 24 b facing the starch-based particles.That heat seal coating may cover, for example, 80%-100% of the surface.

In some embodiments, the first web 22 and/or second web 24 may be formedof a fiber-based material, such as: kraft paper, extensible kraft paper,fiberboard, or recycled fiberboard. The fiber, for example, may comprisewood fiber, bagasse, and/or bamboo. Notably, in some embodiments, thefirst and/or second web may be formed of other material. In someembodiments, the first and/or second web may be recyclable.

In some embodiments, the internal padding (e.g., shown as starch-basedparticles 40 in FIG. 2 ) may be a foam material. The foam material maybe produced using one or more extruder steps to compound and expandstarch-based formulations. Example starch-based formulations includestarch at 60%-99.5% of the total infeed mixture by dry mass; aplasticizer (e.g., preferably biodegradable, and more preferablycompostable) such as PVOH, PVAc, PBS, PBAT, PLA, or Lignin at 0.5%-40%of the total infeed mixture by dry mass; a nucleating agent such as PCCor Sodium Bicarbonate at 0.01%-2% of the total infeed mixture by drymass; a foaming aid such as Sodium Bicarbonate at 0.01%-2% of the totalinfeed mixture by dry mass; and/or a color modifier such as a dye orLignin, preferably Kraft Lignin.

In some embodiments, the foam material may be produced using an aqueousstarch-based formulation that is expanded by heating via one or more of:radio frequency (RF), microwave, infrared (IR), and hot air convection.Such example starch-based formulations may include starch at 20%-60% ofthe total infeed mixture by wet mixture; a water-soluble plasticizersuch as PVOH, PVAc, or glycerol at 0.5%-30% of the total infeed mixtureby wet mixture; a foaming aid such as Sodium Bicarbonate or LauramineOxide at 0.01%-5% of the total infeed mixture by wet mixture; astructural filler such as cellulose pulp or wood pulp at 0.1-50% by wetmixture; and/or a color modifier such as a dye or Lignin. As will bediscussed herein, color dyes such as lignin, may cause the starch-basedpadding to appear close in color to the first web and second web,thereby being visually more uniform, as there may be no distinctionbetween the starch-based padding and the first and second webs. Notably,in some embodiments, water could be used instead of Sodium Bicarbonateor Lauramine Oxide as a foaming aid, such as via conversion to steam. Insome embodiments, the foaming aid or a blowing agent can includewater/moisture content that converts to steam, such as in a hightemperature extrusion process, to create the foam material. In someembodiments, no foaming aid may be utilized.

In some embodiments, the foam may be compressed after expansion to areduced thickness compared to the initial expanded thickness in order toimprove the conformability of the material construction and resilienceof the material construction to repeated impacts by removing initialplastic compression behavior. To explain, the initial foam structureexperiences a relatively large ratio of plastic deformation to elasticdeformation from the first impact compared to subsequent impacts. Saiddifferently, when a foam undergoes an impact or a crushing force, thefirst application of force causes the foam to reduce in thickness,thereby increasing the density, as the air within the foam may bedispelled. However, when the foam undergoes subsequent impacts, thechange in the density decreases with each impact. Thus, between theoriginal form and the second impact there may be a large change indensity of the foam, and a large change in thickness of the foam. Thesechanges cause the padding characteristics to change, which may beundesirable in a package where constant padding characteristics aredesired. Thus, utilizing a precrush provides a “locked-in” desireddensity and thickness of the starch-based foam, thereby providing thedesired density, and resilience of the padded material for use inpackaging.

The compression may be performed by applying pressure in the range 1-200psi, preferably in the range of 5-30 psi. For example, one or more crushdevices may apply pressure to the starch-based padding (e.g., particles,sheet form, etc.) in conjunction with or after being applied on thefirst web 22. In some embodiments, the starch-based padding has aninitial density before compression of between 0.5 lbs/ft³-2.0 lbs/ft³,preferably 0.75 lbs/ft³-1.5 lbs/ft³, and most preferably between 0.75lbs/ft³-1.0 lbs/ft³, and a final density after compression between 1.25lbs/ft³-2.75 lbs/ft³, preferably between 1.5 lbs/ft³-2.5 lbs/ft³ andmore preferably between 1.5 lbs/ft³-2.25 lbs/ft³ In some embodiments,other density ranges may be utilized, however, the present rangeprovides maximum cushioning while minimizing the overall weight of thepadded material, thereby keeping similar shipping costs, when comparedto a conventional padding material.

In some embodiments, the starch-based padding may be formed as aplurality of starch-based particles 40, as illustrated in FIG. 2 . Insome embodiments, prior to compression the starch-based particles 40 maybe spherical, while after compression the starch-based particles 40 maybe more oblong. The starch-based particles 40 may define a particlediameter P_(D) between about 0.15 in -0.45 in, preferably between about0.2 in-0.40 in, and most preferably between about 0.25 in-0.35 in. Insome embodiments, the starch-based particles 40 may define a particlethickness P_(T) between about 0.05 in-0.30 in, preferably between about0.10 in-0.25 in, and most preferably between about 0.15 in-0.20 in. Insome embodiments, the particle thickness P_(T) may be measured after thecompression.

As will be discussed further herein, in some embodiments, thestarch-based padding may be adhered to the first web and/or second webusing a recyclable adhesive/fluid, such as: a starch-based adhesive,PVAc, PVOH, or water. In some embodiments, the recyclable adhesive orwater may moisten the first surface 22 a of the first web 22 prior tocontact with the starch-based padding. Upon contact with the moistenedfirst surface 22 a of the first web 22, the portion of the starch-basedpadding may become tacky and thereby adhere to the first surface 22 a ofthe first web 22. Similarly, the second layer of heat seal coating 34may be moistened with either the recyclable adhesive or water prior toapplication onto the starch-based padding (e.g., a plurality ofstarch-based particles 40). Upon contact with the moistened second heatseal coating layer 34 the starch-based padding become tacky and adheresto the second layer of heat seal coating 34. However, the second layerof heat seal coating 34 may be cured prior to moistening with therecyclable adhesive or water. In this regard, the moisture from eitherthe recyclable adhesive or the water will not reactivate the heat sealcoating or cause the heat seal coating to break down. Thus, in suchexample embodiments, the starch-based padding is adhered to the secondlayer of heat seal coating 34 and second surface 22 b of the first web22.

In some embodiments, a moisture barrier coating for improving waterresistance of the finished products (such as padded mailers) may beadded. The moisture barrier coating, for example, may be added to thefirst web 22 (e.g., on the first surface 22 a or the second surface 22b) and/or the second web 24 (e.g., on the first surface 24 a or thesecond surface 24 b). In some embodiments, the moisture barrier coatingmay be applied to cover between 80-100% of the surface of either thefirst web and/or the second web. The moisture barrier coating may have aformulation comprising, for example: paraffinic wax emulsion, PVOH, VAEemulsion, sterylated melamine, acrylic, and/or latex.

In some embodiments, the moisture barrier coating may be combined withthe heat seal coating to provide both functions in one coating layer.

In some embodiments, one or more of the first web 22 or the second web24 may be printed on. The print may be applied either before or afterany heat seal coating and/or water resistance coatings are applied. Suchprinting may correspond with downstream usage of the padded material.For example, a company name or logo may be printed on one of the webs.

Depending on the desired characteristics of the padded material,different thicknesses of the padded material may be obtained. Forexample, the combined thickness of the padding with the first web andthe second web may be in the range of 0.05 in-0.5 in, preferably in therange of 0.125 in-0.275 in, and most preferably in the range of 0.15in-0.2 in.

In some embodiments, the combined structure of padding, first web, andsecond web may have a width dimension and a length dimension which isperpendicular to the width dimension. The width dimension may besignificantly smaller than the length dimension; for example, a widthdimension may be in the range of 15 in-40 in and a length dimension maybe in the range of 100 ft -1,500 ft.

In some embodiments, the starch-based padding (e.g., the starch-basedparticles) may be placed in a pattern on the first web. The specificpattern may create desired spacing between one or more starch-basedparticles. The specific pattern may provide beneficial properties, suchas increased padding protection, reduced material usage, easier assemblyor formation of products (e.g., a padded mailer), among other things.

FIG. 3 shows a portion of the roll of padded material shown in FIG. 1with the second web removed to show the starch-based particles 40positioned on the first web 22. In some embodiments, the starch-basedparticles 40 may cover between 10%-60% of the first web 22, preferablybetween 20%-40% of the first web 22, and more preferably thestarch-based particles 40 may cover about 25% of the first web 22. Insome embodiments, different coverage may be required depending on thecomposition and density of the starch-based particles 40, such asbetween 25%-50% coverage. In this regard, in some embodiments, when thestarch-based particles are more resilient (e.g., measured as the amountof degradation of the starch-based particles from subsequent impacts),less particles may be needed to achieve the desired cushioningproperties. In contrast, for starch-based particles exhibiting lowresiliency a higher number of starch-based particles may be needed tocover a larger area of the first web to achieve the desired cushioningproperties.

Cushioning performance testing was performed on 5 different examplecoverage ratios of starch-based particles to air gaps, with eachotherwise using the same starch-based particular formulation, the samepattern, the same thickness (e.g., within a range of 0.15 in to 0.3 in),and the same density (e.g., within a range of 0.8 lbs/ft³-2.0 lbs/ft³).The 5 different example padded material with different coverage ratiosincluding padded material with (A) 50% starch-based particle coverage,(B) 40% starch-based particle coverage, (C) 30% starch-based particlecoverage, (D) 25% starch-based particle coverage, and (E) 15%starch-based particle coverage.

Five consecutive impacts of the same amount of force were applied toeach example padded material and the peak acceleration, measured as g(the standard acceleration due to Earth's gravity, equivalent tog-force), was measured for each impact. The impacts that were applied tothe samples were delivered by a drop tower purpose built for testingcushion materials. The drop tower is fitted with a velocity gate formeasuring impact velocity and accelerometers for measuring theacceleration at impact. The drop tower can reproducibly drop a flatplaten with adjustable mass and drop height onto the samples inquestion. The platen is guided by two rails so that it is orientedproperly at impact. Due to the nature of free fall, and some smallfrictional losses on the guide rails, the velocity of each impact is notexactly the same but they are very close (e.g., within +/−1 in/s). Theimpacts that were applied to the samples in question involved dropping a12.8 lbs (5.81 kg) platen from an effective freefall drop height of 5 in(0.127 m), resulting in an impact velocity of 62 in/s (1.57 m/s). Theenergy of such an impact can be calculated as 7.2 Joules. Table 1 belowillustrates the results of the consecutive impact testing on eachexample padded material.

TABLE 1 IMPACT IMPACT IMPACT IMPACT IMPACT SAMPLE 1 2 3 4 5 (A) 50%136.8 156.5 165.3 172.2 181.3 coverage (B) 40% 134.9 162.5 182.6 192.8208.3 coverage (C) 30% 162.8 199.9 236.7 258.1 272.0 coverage (D) 25%191.7 250.1 313.4 361.6 412.8 coverage (E) 15% 298.6 525.0 699.4 789.3908.2 coverage

With reference to results shown in Table 1, sample (E) formed of 15%starch-based particle coverage performed the worst, where impacts 2-5yielded undesirable peak acceleration measurements above 500 g. However,even sample (D) at only 25% starch-based particle coverage maintainedgood peak acceleration measurements below 500 g even during a 5^(th)impact. Such testing illustrated desirable cushioning was achieved with25%-50% starch-based particle coverage.

FIG. 4A illustrates a close up schematic-type view of the roll of paddedmaterial. In the illustrated embodiment, the starch-based particles 40occupy about 50% of the first web 22, and about 50% of the first web 22comprises an air gap 49, where the second surface of the first web 22 isexposed. In some embodiments, the air gap 49 may define a distance D_(P)between each of the starch-based particles 40, in this regard, todecrease the coverage of the starch-based-particles, the distance D_(P)between each of the starch-based particles 40 may be increased. Each ofthe starch-based particles 40 may be spaced apart on all directions,said differently, the starch-based particles may not overlap. In someembodiments, the distance D_(P) may be in the range of 0.01 in-2 in,preferably in the range of 0.1 in-1 in.

In some embodiments, the first web 22 may define a fold region 45 withinthe pattern. In some embodiments, the fold region 45 may create a foldline for forming packaging out of the padded material. In this regard,the lack of starch-based particles 40 in the fold region 45 creates anatural fold line, as there are no starch-based particles 40 beingcrushed or manipulated to fold the padded material therealong.

FIG. 4B illustrates a close up view of another example pattern for thepadded material. This illustrated pattern comprises the plurality ofstarch-based particles 40, at a coverage of about 25% of first surfaceof the first web 22, with about 75% air gap 49 along the first surfaceof the first web 22. Notably, other patterns and coverage ratios ofstarch-based padding to air gaps are contemplated.

FIG. 5 shows a schematic representation of an example system 100 forforming padded material, such as the padded material described herein.The system 100 may, such as through controller 190, cause conveyance ofone or more paper-based webs, such as along the machine direction (MD)arrow. For example, one or more conveyor means (e.g., a conveyor belt,one or more rollers, etc.) and/or motors may be used to cause a roll 121of a first web 122 to pass through a print phase 160, a seam adhesiveapplication phase 165, a heat seal coating applicator phase 130, anadhesive/fluid applicator phase 150, a padding applicator phase 170,and/or a crush device phase 155. After that, the conveyor means maycause the first web 122 to combine with the second web 124 (such as froma roll 123 of the second web 124) at a combination point 129 to form thepadded material 120. FIG. 8A illustrates an additional example system200 for forming a second padded material 220 as described herein.

Notably, in conjunction with various embodiments described herein,various of the phases can be combined, changed in order of operation,separated, or otherwise changed. In such example embodiments, thecorresponding phases may be adjusted accordingly.

The following provides further example description of the variousfeatures/components and/or phases corresponding to systems 100, 200. Inthis regard, depending on the type of padded material (e.g.,starch-based particles, or expanded starch-based sheet(s)), differentfeatures/components may be employed. The controller 190 provides logicand control functionality used during operation of the system 100. Insome embodiments, the functionality of the controller 190, 290 may bedistributed to several controllers that each provides more limitedfunctionality to discrete portions of the operation of system 100, 200.The controller 190, 290 may comprise one or more suitable electronicdevice(s)/server(s) capable of executing described functionality viahardware and/or software control. In some embodiments, the controller190, 290 may include one or more user interfaces (not shown), such asfor displaying information and/or accepting instructions. The controller190, 290 can be, but is not limited to, a microprocessor, microcomputer,a minicomputer, an optical computer, a board computer, a complexinstruction set computer, an ASIC (application specific integratedcircuit), a reduced instruction set computer, an analog computer, adigital computer, a molecular computer, a quantum computer, a cellularcomputer, a solid-state computer, a single-board computer, a bufferedcomputer, a computer network, a desktop computer, a laptop computer, apersonal digital assistant (PDA) or a hybrid of any of the foregoing.

The controller 190, 290 may include one or more processors coupled to amemory device. Controller 190, 290 may optionally be connected to one ormore input/output (I/O) controllers or data interface devices (notshown). The memory may be any suitable form of memory such as an EPROM(Erasable Programmable Read Only Memory) chip, a flash memory chip, adisk drive, or the like. As such, the memory may store various data,protocols, instructions, computer program code, operational parameters,etc. In this regard, the controller 190, 290 may include operationcontrol methods embodied in application code. These methods are embodiedin computer instructions written to be executed by one or moreprocessors, typically in the form of software. The software can beencoded in any suitable language, including, but not limited to, machinelanguage, assembly language, VHDL (Verilog Hardware DescriptionLanguage), VHSIC HDL (Very High Speed IC Hardware Description Language),Fortran (formula translation), C, C++, Visual C++, Java, ALGOL(algorithmic language), BASIC (beginners all-purpose symbolicinstruction code), visual BASIC, ActiveX, HTML (HyperText MarkupLanguage), and any combination or derivative of at least one of theforegoing. Additionally, an operator can use an existing softwareapplication such as a spreadsheet or database and correlate variouscells with the variables enumerated in the algorithms. Furthermore, thesoftware can be independent of other software or dependent upon othersoftware, such as in the form of integrated software. In this regard, insome embodiments, the controller 190 may be configured to executecomputer program code instructions to perform aspects of variousembodiments of the present invention described herein.

The controller 190, 290 may be operably coupled with one or morecomponents of the system 100, 200 including for example, the roll 121,221 of the first web 122, 222 (or corresponding web management devicefor controlling translation of the first web 122, 222 along the webpath), the roll 123, 223 of the second web 124, 224 (or correspondingweb management device for controlling translation of the second web 124,224 along the web path), various components of the printing phase 160,260, various components of the seam adhesive application phase 165, 265,various components of the heat seal coating applicator phase 130, 230,various components of the senate and stretch phase 268, variouscomponents of the adhesive/fluid applicator phase 150, 250, variouscomponents of the padding applicator phase (e.g., 170 utilizing thesupply 177 and/or extruder 175 for, for example, starch-based particlesor utilizing the supply 277, extruder 275, and serrate/stretch 268 for,for example, starch-based sheet(s)), various components of the crushdevice phase 155, 255, conveyance means of the system 100, 200 and othercomponents (such as described herein). For example, depending on thecomponents, the controller 190, 290 may be operably coupled such asthrough use of solid-core wiring, twisted pair wiring, coaxial cable,fiber optic cable, mechanical, electrical, wireless, radio, infrared,etc. In this regard, depending on the components, the operable couplingmay be through one or more intermediate controllers or mechanicalcoupling, such as used for controlling some components (e.g.,controlling operation and/or feeding of the roll 121, 221 of the firstweb 122, 222). In some embodiments, the controller 190, 290 may beconfigured to provide one or more operating signals to these componentsand to receive data from these components.

During the printing phase 160, 260, the controller 190, 290 may direct aprinter to print one or more images at specific locations on the firstweb 122, 222. Any image (including words, markers, instructions, etc.)is contemplated by various embodiments of the present invention. Forexample, various labels corresponding to the padded mailer may beprinted onto the first web (such as the face of the first web that willface outside of the padded mailer). As another example, a barcode orother identifier may be printed to be used, such as during shippingand/or delivery. Although the example figures show the first webundergoing printing, in some embodiments, in addition to or in thealternative, the second web 124, 224 may undergo printing through theprinting phase 160, 260.

During the seam adhesive application phase 165, 265, the controller 190,290 may be configured to cause application, such as from a seam adhesiveapplication device, of adhesive onto the first web 122, 222. Forexample, such adhesive may be applied to ultimately help form the seamin conjunction with a corresponding portion of the second web 124, 224.The seam adhesive may be any type of adhesive that enables adherencebetween the first web and the second web. In some embodiments, otherconfigurations or applications of the seam adhesive are contemplated,such as applying the seam adhesive to the second web 124, 224 (e.g., inaddition to or in the alternative to applying the seam adhesive to thefirst web 122, 222). The seam adhesive may enable edges of the first web122 and the second web 124 to be joined together thereby sealing theplurality of starch-based particles therein.

During the heat seal coating applicator phase 130, 230, the controller190, 290 may be configured to cause application, such as from a heatseal coating application device, of heat seal coating onto the first web122, 222, such as described herein. Notably, a corresponding heat sealcoating applicator phase 130, 230 may be utilized to apply heat sealcoating to the second web 124, 224, such as described herein. As notedherein, the heat seal coating may be used to seal the webs togetherand/or used in later conversion stages, such as during formation of apadded mailer.

During the adhesive/fluid applicator phase 150, 250, the controller 190,290 may be configured to cause application, such as from an adhesive orfluid application device, of adhesive or other fluid (e.g., water,water-based fluid, etc.) onto the first web 122, 222, such as describedherein. Notably, a corresponding adhesive/fluid applicator phase 150,250 may be utilized to apply adhesive or other fluid to the second web124, 224, such as described herein. As noted herein, the adhesive orother fluid may be used to adhere and/or otherwise connect thestarch-based particles to the first web 122, 224.

During the padding applicator phase 170, the controller 190 may beconfigured to cause application, such as from an applicator, of thestarch-based particles 140 onto the first web 122, such as describedherein. Notably, such application of the starch-based particles may bepositioned according to a specific pattern. The starch-based particles(or other padding) may be formed by an extruder 175 that receivedmaterials from a supply 177 (e.g., storage area or similar). Examplesystems with more specific detail regarding example applicationprocesses for the starch-based particles are illustrated in FIGS. 6A-6Fand are described further herein. Notably, while the crush device phase155 is shown separate from the padding applicator phase 170, in someembodiments, it may occur in conjunction with the padding applicatorphase 170.

During the crush device phase 155, the controller 190 may be configuredto cause crushing of the starch-based particles 140 on the first web122, such as described herein. Such crushing may include applying one ormore instances of pressure to the starch-based particles (e.g., eitherdirectly to the particles and/or through one of the first or secondweb). For example, during application, a roller may act on thestarch-based particles just before, during, or after application of thestarch-based particles to the first web. As another example, after thesecond web is brought into contact (e.g., brought together) with thefirst web with the starch-based particles therebetween, one or morerollers (or other crush devices) may crush the padded material to thedesired properties (e.g., thickness, density, etc.). In someembodiments, different stages of crushing may be applied. For example, afirst set of two rollers of a first width may act on the starch-basedparticles (and/or webs) at a first instance, and then, downstream, asecond set of two rollers of a second (shorter) width may act on thestarch-based particles (and/or webs)—thereby creating a tiered crushingapproach. In some embodiments, additional crushing stations orvariations in widths (such as maintaining a same width or increasing inwidth) between rollers may be applied to the crushing approach.

In some embodiments, the padded material 120 may include one or moreexhaust holes or vents, such as formed pin holes, punched holes, orsimilar formed on the first web 122. For example, an additional exhausthole creation phase may be applied to the padded material 120 to formthe one or more exhaust holes for vents (although, in some embodiments,the exhaust holes may be formed when the first and second webs arebrought together, such as by not sealing one or more portions of thefirst and second webs together). Such one or more exhaust holes or ventsmay enable air to escape, such as during handling (e.g., duringshipping, if the padded material is dropped or otherwise impacted,etc.), during passage of the padded material through a nip of rollers orother components during various manufacturing processes, among othercircumstances.

In some embodiments, the one or more exhaust holes or vents may beformed in the internal web (e.g., the first web 122). In this regard,the one or more exhaust holes or vents may provide means for air toescape, while maintaining a seal about the package to prevent directmoisture ingress. Further, the one or more exhaust holes or vents mayprovide an escape route for released moisture during heating and/ordrying of the padded material and/or package. In other embodiments, theone or more exhaust holes or vents may be positioned within the sideseal to cause the internal pressure of the package to return to anequilibrium during pressure changes.

Before, after, or during the crush device phase 155, the first web 122(and starch-based particles 140) and the second web 124 (coming from asecond roll 123) may be brought together (e.g., combined) at connectionpoint 129 to form the padded material 120. Thereafter, the paddedmaterial 120 may be rolled up into a roll, such as shown in FIG. 1 .

FIG. 6A illustrates a schematic representation of a portion of theexample system for forming a padded material, such as discussed herein.The system illustrated in FIG. 6A is a portion of the system illustratedin FIG. 5 , in that it includes the first roll 121 holding the first web122, the second roll 123 holding the second web 124, starch-basedparticles 140, an adhesive/fluid and/or heat seal coating applicator130/150, and a crush device 155. The system illustrated in FIG. 6Aexpands on the applicator phase, including a hopper 173 and a vacuumwheel 180 (although any vacuum-based device is contemplated, such as abelt or other transfer device). Notably, the vacuum wheel 180 “grabs”the starch-based particles 140 directly from hopper 173 and thendeposits them on the first web 122.

FIGS. 6B-6F show example devices that may be used in the applicatorphase 170. FIG. 6B illustrates a side view of one or more devicesutilized in the applicator phase 170. In some embodiments, the pluralityof starch-based particles are supplied to the hopper 173 through aninlet 177. The inlet 177 may be connected directly to an extruder, orother supply means of the starch-based particles 140. The plurality ofstarch-based particles 140 may reside in the hopper 173 untiltransferred, via the vacuum wheel 180, to the first web.

In some embodiments, the hopper 173 comprises an acceleration device191, which spans the width of the hopper 173 (e.g., along the width ofthe vacuum wheel 180). In some embodiments, the acceleration device 191may be configured to accelerate the plurality of starch-based particles140 such that the speed of the plurality of starch-based particles 140is about the speed of the vacuum wheel 180 (e.g., the rotation impartedon the starch-based particles 140 by the acceleration device 191 causesthe starch-based particles 140 to accelerate so as to travel at aparticle rotational speed that matches a vacuum wheel rotational speedfor engagement of the plurality of starch-based particles with thevacuum wheel). In this regard, the acceleration device 191 provides apoint of acceleration which accelerates the plurality of starch-basedparticles past the terminal velocity. The acceleration of the pluralityof starch-based particles 140 to about the speed of the vacuum wheel 180increases the fill ratio by causing a higher chance of capture. In someembodiments, the acceleration device 191 may increase the velocity ofthe starch-based particles to over 200 ft/min.

In some embodiments, the acceleration device may be formed as any devicethat can carry, push, or feed the plurality of starch-based particles tothe vacuum wheel 180, for example, a moving belt, moving plates, abrush, moving pockets, a drum, or similar.

With reference to FIG. 6D, the acceleration device 191 may be a brushspaced apart from the vacuum wheel 180. In some embodiments, theacceleration device 191 may define a diameter of about 4″. The size ofthe acceleration device 191, may contribute to a single layer ofstarch-based particles 140 engaging with the vacuum wheel 180 at a givenrotation. Further, the vacuum wheel 180 may rotate in a first direction(e.g., clockwise) and the acceleration device 191 may rotate in a seconddirection (e.g., counterclockwise). Thus, both the vacuum wheel 180 andthe acceleration device 191 may drive the starch-based particles 140upwards (e.g., away from the plurality of starch-based particles 140within the hopper 173 as illustrated in a theoretical manner in FIG.6D).

In some embodiments, the acceleration device 191 may be positionedbetween 0.1 in-0.3 in from the vacuum wheel 180. The space between thevacuum wheel 180 and the acceleration device 191 preferably allows theplurality of starch-based particles 140 to pass between the accelerationdevice 191 and the vacuum wheel 180 without being crushed, whilepreventing back slippage. In some embodiments, the distance between thevacuum wheel 180 and the acceleration device 191 may be measured fromthe bristles of the acceleration device 191 to the surface of the vacuumwheel 180. In some embodiments, the bristles of the acceleration device191 are malleable such that they may encapsulate the plurality ofstarch-based particles 140 without crushing them. Additionally oralternatively, in some embodiments, the acceleration device 191 maycomprise a plurality of fins spaced about the circumference, whereineach of the fins comprise bristles at the top of the fins. In someembodiments, the acceleration device 191 may aid in capture of each ofthe starch-based particles 140 within one of the bore holes present onthe vacuum wheel 180.

Returning to FIG. 6B, the application phase 170 may include a levelcontrol device 192, which may span the width of the hopper 173. Thelevel control device 192 may be positioned to work with the accelerationdevice 191 and may be configured to distribute the plurality ofstarch-based particles 140 more evenly to the acceleration device 191.In this regard, without the level control device 192, the starch-basedparticles may congregate towards a center of the hopper (e.g., midwidth), such that the starch-based particles are not evenly distributedon the acceleration device 191, and thus, the vacuum wheel 180. Thus,the level control device 192 distributes the plurality of starch-basedparticles 140 to the acceleration device 191.

With reference to FIG. 6E, in some embodiments, the level control device192 may comprise fins 193 disposed about its circumference. In someembodiments, the fins 193 may comprise bristles attached to the ends ofthe fins for easier engagement of the starch-based particles 140. Insome embodiments, the level control device 192 may be configured as abrush. The rotation of level control device 192 may “pick up” a portionof the plurality of starch-based particles 140 within the hopper 173 andcause the plurality of starch-based particles 140 to distribute alongthe width of the level control device 192 and thereby be more uniformlydelivered to the acceleration device 191.

In some embodiments, the level control device 192 may be positionedbetween 1 in-4 in from the vacuum wheel 180. The distance between thelevel control device 192 and the vacuum wheel 180 may prevent any of theplurality of starch-based particles 140 engaged with the level controldevice 192 from engaging with the vacuum wheel 180 prior to beingaccelerated by the acceleration wheel 180.

Returning to FIG. 6B, in some embodiments, the application phase 170 mayfurther comprise a cage 174. The cage 174 may be an extension of thehopper 173 positioned opposite the inlet 177. In this regard, the cage174 may comprise a plurality of openings which may allow air flow, whilepreventing the plurality of starch-based particles 140 from escaping.With reference to FIG. 6C, the cage 174 may be positioned above thevacuum 180, so as to not impede rotation of the vacuum wheel 180.

Returning to FIG. 6B, in some embodiments, the application phase 170 mayfurther comprise an air knife 185 positioned above the vacuum wheel 180.The air knife 185 may be positioned outside of the hopper at the pointwhere the plurality of starch-based particles 140 exit the hopper 173 onthe vacuum wheel 180. The air knife 185 may direct a stream of airtangentially along the surface 182 of the vacuum wheel 180 to blow backany excess particles. Excess particles may be, for example, particlesstacked on top of other particles, or particles on the surface 182rather than in a counter bore 181 (see e.g., FIG. 6F).

Each of the plurality of particles 140 may exit the hopper 173 engagedwith the vacuum wheel 180. With reference to FIG. 6C, the vacuum wheel180 is configured to hold (e.g., via vacuum suction) one of theplurality of particles 140 within each of the counter bores (see e.g.,181 FIG. 6F) to create the desired pattern on the web. Although FIG. 6Cis illustrated as though each of the plurality of starch-based particles140 abuts one another, except within a fold region 145, it should beunderstood, that the surface 182 of the vacuum wheel 180 may define thedesired pattern, and the plurality of starch-based particles 140 occupythe desired pattern.

FIG. 6F illustrates a spacing pattern of the vacuum wheel 180. Thesurface 182 of the vacuum wheel 180 may comprise a series of openings181 formed in the desired spacing pattern. In some embodiments, theopenings 181 may define a bore width B_(W) extending latitudinally alongthe vacuum wheel 180, and a bore height B_(H) extending longitudinallyalong the vacuum wheel 180. In some embodiments, due to the curvature ofthe vacuum wheel surface 182 the opening 181 spacing may be differentthan the desired spacing as discussed herein, however the spacing of theopenings 181 creates a pattern on the first web wherein each of thestarch-based particles is spaced apart from one another, saiddifferently the spacing of the openings 181 prevents overlap betweenadjacent starch-based particles when positioned on the web. In someembodiments, the bore width B_(W) may be between about 0.95 in-1.2 in,preferably between 1.0 in-1.1 in, and more preferably about 1.06 in. Insome embodiments, the bore height B_(H) may be between about 0.5 in-1.0in, preferably between about 0.65 in-0.9 in, and more preferably about0.74 in.

Each of the openings 181 may be configured to retain one of theplurality of starch-based particles through the rotation from the hopperto application on the first web. In this regard, in some embodiments,the openings 181 may comprise vacuum suction to secure the plurality ofstarch-based particles within or to the opening 181. In someembodiments, the openings 181 may define a shape configured to, with theassistance of vacuum suction, retain the plurality of starch-basedparticles within the opening. The openings 181 may be, for example,cylindrical, cupped, stepped, countersink, counter bore or a combinationthereof throughout the vacuum wheel surface 182.

In some embodiments, the plurality of openings 181 may be configured toretain each of the starch-based particles on the vacuum wheel surface182, while in other embodiment the openings 181 may be configured toretain each of the starch-based particles partially below the vacuumwheel surface 182. Still in further embodiments the openings 181 may beconfigured to retain each of the starch-based particles such that theentire starch-based particle is below the vacuum wheel surface 182. Insome embodiments, the depth of the plurality of starch-based particleswithin the opening 181 may allow the plurality of particles to bebrought into contact with the web for improved contact, compressionand/or adhesion, while preventing contact between the web and the vacuumwheel surface 182. In this regard, if the web (e.g., the moistenedsurface of the web) is brought into contact with the vacuum wheelsurface 182, the moisture may transfer from the web to the vacuum wheelsurface 182, which may cause moisture ingress into the hopper and theplurality of starch-based particles therein. Moisture present in thehopper may cause the plurality of starch-based particles to stick to oneanother, the acceleration device 191, the level control device 192, thehopper and/or other components within the application phase 170. Thus,the depth of the openings 181 may be configured to encourage directcontact between the starch-based particle and the web, for accurateplacement, while preventing contact between the web and the vacuum wheelsurface 182.

As discussed, in some embodiments, the openings 181 may be formed ascounter bores. In this regard, the openings 181 181 may be recessedwithin the surface 182 of the vacuum wheel 180. In some embodiments, theopening 181 may define an sloping surface between the vacuum wheelsurface 182 and the depth of the openings 181. In this regard, theopening 181 may define an upper radius B_(DU) which extends from thecenter of the opening 181 to the surface of the vacuum wheel 182, and alower radius B_(DL) which extends from the center of the opening 181 tothe edge of the lower surface. In some embodiments, the opening upperradius B_(DU) may be about 0.34 in and the opening lower radius B_(DL)may be about 0.27 in. As mentioned each of the opening 181 are recessedwithin the surface 182 of the vacuum wheel. In some embodiments, therecess is about 0.075 in deep, thereby creating about a 25 degree draftfrom the opening upper radius B_(DU) to the opening lower radius B_(DL).

In some embodiments, the openings 181 comprise a vacuum hole 173disposed at the center of the opening 181. The vacuum hole 183 maydefine a vacuum hole diameter of about 0.1 in and may define a 15 degreeoutward draft to the opening lower radius B_(DL). In this regard, thevacuum drum 180 may be in fluid communication with a vacuum source toprovide vacuum suction in each of the vacuum holes 183.

As noted herein, the starch-based padding may be formed of manydifferent shapes or configurations. In this regard, FIGS. 7A-8Billustrate embodiments where the starch-based padding is formed of astarch-based sheet (e.g., instead of a plurality of starch-basedparticles). In this regard, FIGS. 7A-B illustrate a padded material 220formed with an expanded starch-based sheet 242. FIG. 7A illustrates thepadded material 220 with a portion of a second web 224 removed to showthe expanded starch-based sheet 242 on a first web 222. In someembodiments, the expanded starch-based sheet 242 may comprise air gaps249 formed as the expanded starch-based sheet is stretched to achievethe desired padding coverage. With reference to FIG. 8B, as an example,the air gaps 249 may be formed when an extruded starch-based sheet 241is cut with a die cut 258 comprising knives 259 disposed in a desiredpattern. After the extruded starch-based sheet 241 is cut, the sheet maybe pulled under tension to expand the starch-based sheet 242 to achievethe desired coverage.

Returning to FIG. 7A, multiple sheets of the expanded starch-based sheet242 may be positioned on the first web 222 such as to form a foldregion. FIG. 7B shows a cross-sectional view of the example paddedmaterial 220 taken along line 7B-7B in FIG. 7A. The padded material 220utilizing the expanded starch-based sheet comprises a similarcomposition to the padded material 20 utilizing starch-based foamparticles 40 (e.g., FIG. 2 ). In this regard, a first heat seal coatinglayer 232 may be applied to an outer surface of the first web 222, and asecond heat seal coating layer 234 may be applied to an inner surface ofthe second web 224 such that the second heat seal coating layer 234contacts both the second web 224 and the expanded starch-based sheet242.

FIG. 8A illustrates a schematic representation of an example system 200for forming padded material 220, such as the expanded starch-based sheet242 described herein. The system 200 may be configured similar to system100 as discussed with reference to FIG. 5 . In this regard, as discussedthe system 200 may, such as through controller 290, cause conveyance ofone or more paper-based webs, such as along the machine direction (MD)arrow. For example, one or more conveyor means (e.g., a conveyor belt,one or more rollers, etc.) and/or motors may be used to cause a roll 221of a first web 222 to pass through a print phase 260, a seam adhesiveapplication phase 265, a heat seal coating applicator phase 230, anadhesive/fluid applicator phase 250, and/or a padding applicator phase270. After that, the conveyor means may cause the first web 222 tocombine with the second web 224 (such as from a roll 223 of the secondweb 224) at a combination point 229 to form the padded material 220.

Notably the print phase 260, the seam adhesive phase 265, the heat sealcoating applicator phase 230, and the adhesive/fluid applicator phase250, may be the same as the corresponding phase in system 100. Thesupply phase 277, extruder phase 275, serrate/stretch phase 268, andapplicator phase 270 may vary from corresponding phases in system 100.

During the supply phase 277, the controller 290 may be configured tocause and/or monitor the supply of materials for the starch-based sheetbeing provided to the extruder. In the extruder phase 275, thecontroller 290 may be configured to cause the components from the supply277 to form the extruded starch-based sheet. In some embodiments, theextruder phase 275 may produce a continuous sheet, which has a widthsuited for the first web 222 and the second web 224 (or a correspondingwidth that is desirable—such as when two or more sheets are utilized forthe first and second web). In some embodiments, the width of thestarch-based sheet may be between about 10 in-30 in. The starch-basedsheet 224 may be formed to have a uniform thickness.

During the serrate/stretch phase 268, with reference to FIG. 8B, thestarch-based sheet 241 may pass through the die cut 258 comprisingknives 259 disposed to form a desired pattern. The cuts formed in thestarch-based sheet 241 allow the sheet to be expanded (e.g., stretched)such that the cuts in the foam become air gaps (e.g., 249 FIG. 7A). Toexpand the starch-based sheet tension may be applied in the machinedirection to expand the starch-based sheet to a length which is largerthan the initial length. The tension creates air gaps (e.g., 249 FIG.7A) to open up, while the starch-based sheet remains intact and iscontinuous along the sheet. For example, in some embodiments, theserrate/stretch phase 268 causes the starch-based sheet 241 thatinitially had 100% surface coverage of the first web 222 to be expandedso as to reduce the coverage down to a desired amount, for example,about 25%. Returning to FIG. 8A, during the serrate/stretch phase 268,the controller 290 may be configured to cause rotation of the die cut258, such as to position the cuts in the desired location. Further, thecontroller 290 may be configured to apply tension to the starch-basedsheet 241 to create the desired coverage.

During the padding applicator phase 270, the controller 290 may beconfigured to cause application, such as from an applicator, of theexpanded starch-based sheet 242 onto the first web 222, such asdescribed herein. Notably, a crush device phase may occur in conjunctionwith the padding applicator phase 270.

During the padding applicator phase 270, as illustrated in FIG. 8B, thecontroller 290 may be configured to cause crushing of the extrudedstarch-based sheet 242 on the first web 222, such as described herein.Such crushing may include applying one or more instances of pressure tothe expanded starch-based sheet 242 (e.g., either directly to the sheetand/or through one of the first or second web). For example, duringapplication, a roller may act on the extruded starch-based sheet justbefore, during, or after application of the expanded starch-based sheetto the first web. As another example, after the second web is brought incombination with the first web with the starch-based sheet therebetween,one or more rollers (or other crush devices) may crush the paddedmaterial to the desired properties (e.g., thickness, density, etc.). Insome embodiments, different stages of crushing may be applied. Forexample, a first set of two rollers of a first width may act on thestarch-based sheet (and/or webs) at a first instance, and then,downstream, a second set of two rollers of a second (shorter) width mayact on the starch-based sheet (and/or webs)—thereby creating a tieredcrushing approach. In some embodiments, additional crushing stations orvariations in widths (such as maintaining a same width or increasing inwidth) between rollers may be applied to the crushing approach.

During the padding applicator phase 270, the first web 222 (and expandedstarch-based sheet 242) and the second web 224 (coming from a secondroll 223) may be brought together (e.g., combined) at connection point229 to form the padded material 220. Thereafter, the padded material 220may be rolled up into a roll, such as shown in FIG. 1 .

FIG. 9 shows a schematic representation of an example system using anautomated padded mailer formation device for forming a padded mailerfrom the padded material. The system 500 causes conveyance of the paddedmaterial 520, such as from a first roll 528 (e.g., using one or moreconveyor means, such as a conveyor belt, one or more rollers, etc.,and/or motors). The padded material 520 is passed into an automatedpadded mailer formation device 503. The automated padded mailerformation device 503 may perform various steps or phases on the paddedmaterial 520 to produce a padded mailer with an item contained therein509. For example, the automated padded mailer formation device 503 may,during an insert item and/or fold phase 501, cause the padded material520 be folded around an item. In some cases, the fold may occur anywherealong the width of the padded material. In some cases, the fold mayoccur along a fold line, such as formed in some example padded materialembodiments described herein. Then, during a seal phase 502, the device503 may cause the two portions of the padded material 520 to be sealedtogether in the form of a padded mailer. In some embodiments, pressureand/or heat may be applied to one or more of the edges of the paddedmaterial 520 to cause the heat seal coating and/or other adhesive on thepadded material 520 to adhere together to form the padded mailer.Thereafter, during an apply features phase 504, the device 503 may causeone or more features to be applied to the padded mailer, such as atear-strip. Finally, the device 503, such as during a cut phase 506, maycause the padded mailer to be cut away from the remainder of the paddedmaterial 520—thereby forming the padded mailer with item inside 509.

Notably, in conjunction with various embodiments described herein,various of the phases can be combined, changed in order of operation,separated, or otherwise changed. In such example embodiments, thecorresponding phases may be adjusted accordingly.

Some embodiments of the present invention contemplate other ways tocreate products, such as a padded mailer, from the padded material, asdiscussed with reference to FIG. 13 . For example, a padded mailer withan opening for receiving an item may be formed. Such a padded mailer maythen be “hand” packed with the item.

The padded material as discussed herein may be used in automated packagemachines due to the configuration and position of the heat seal coatinglayers within the padded material. In this regard, the heat seal coatinglayers are configured to seal to the starch-based padding, therebyretaining the starch-based padding within the padded material regardlessof where the padded material is cut and/or sealed. To explain, FIGS.10A-11C illustrate views of mailers formed from an automated packagingmachine, such as discussed with reference to FIG. 9 .

FIG. 10A illustrates a top view of an example package 509 formed with anautomated packaging machine. The package 509 comprises an edge 553extending about the perimeter of the package, and heat seal coating 552disposed along the edge 553. Notably, the top edge 553 a and bottom edge553 c may have been cut and sealed (e.g., via pressure and heatutilizing the heat seal coating layer described herein). The right sideedge 553 b is formed due to folding of the padded material around theitem (which is positioned in the padded area 559). The left side edge553 d may have been sealed after the padded material was folded aroundthe item.

FIG. 10B illustrates a cross-sectional view of the package 509 takenwithin circle B. A first padded material 520 a is positioned adjacent toa second padded material 520 b. In some embodiments, the first paddedmaterial 520 a and the second padded material 520 b may be the samepadded material. In the illustrated embodiment, the first paddedmaterial 520 a comprises a first web 522 and a first layer of heat sealcoating 532 applied to a second surface (e.g., 22 b FIG. 2 ) of thefirst web 522, a second web 524 with a second layer of heat seal coating534 applied to a second surface (e.g., 24 b) of the second web, and aplurality of starch-based particles 540 disposed between the secondlayer of heat seal coating 534 and the first web 522. The second paddedmaterial 520 b may include a similar composition to the first paddedmaterial 520 a, however, the second padded material 520 b may be rotatedsuch that the first layer of heat seal coating 532 of each of the firstpadded material 520 a and the second padded material 520 b may be incontact.

The first layer of heat seal coating 532 may be heated (and/orpressurized) to form a heat seal 552 between the first padded material520 a and the second padded material 520 b. The heat seal 552 may notfully compress the starch-based particles along the bottom edge 553 c.In some embodiments, one of the starch-based particles may be cut due tothe cut bottom edge 553 c forming one or more cut particles 544. Thelignin added to the starch-based particles 540 causes the cut particle544 to have the same approximate color as the first web 522 and thesecond web 524. Thus, the padded material 520 a, 520 b, which is visiblevia the cut bottom edge 553 c, may not create a non-uniform appearance.

In some embodiments, the second layer of heat seal coating 534 may sealand further secure the cut particles 544 to the second web 524 andprevent the plurality of starch-based particles from detaching from thepadded material 520 a, 520 b. Additionally the second layer of heat sealcoating 534 may in some areas create a heat seal with the first web 522between particles of the cut particles 544, thereby furtherencapsulating the plurality of starch-based particles within the paddedmaterial 520 a, 520 b.

FIGS. 11A-C illustrate another example package 300 which may be formedfrom the automated package machine. The package 300 may be formed fromone sheet of padded material 320 defining a first edge 320 a, a secondedge 320 b, a third edge 320 c, and a fourth edge 320 d. In someembodiments, the padded material 320 may be folded (e.g., about the foldregion 44 FIG. 3 ), bringing the second edge 320 b and the fourth edge320 d together, and forming a folded edge 308 opposite thereof. A seamededge 307 may be formed along the edges 320 a, 320 c, 320 b/320 d to sealthe padded material 320 into a package 300.

FIGS. 11B-C illustrate cross-sectional views of the example package 300taken along lines B-B and C-C respectively. FIG. 11B illustrates thepackage 300 formed from a single padded material 320 and folded over afold region 345 which creates the folded edge 308. In the illustratedembodiment, the padded material 320 is folded over the fold region 345to form a pocket 315 for receiving an item 305 to be shipped anddelivered therein. The second layer of heat seal coating 332 may befacing the pocket 315, however, as the heat seal coating is sufficientlycured prior to formation of the package 300 the heat seal coatingmaterial does not transfer to any item 305 placed within the pocket 315.

As noted herein, the padded material may be converted into any number ofproducts, such as padding cut into shapes (e.g., for placement in boxes,storage, etc.) or padded mailers.

FIG. 12A illustrates an example padded mailer 409 contemplated byvarious embodiments of the present invention. The illustrated paddedmailer 409, which is shown in the open, ready for packagingconfiguration, includes a front panel 439 and a back panel 429. Thefront panel 439 defines a width W_(FP) and a length L_(FP) and includesfour edges 439 a, 439 b, 439 c, and 439 d. The back panel 429 defines awidth W_(BP) and a length L_(BP) and includes four edges 429 a, 429 b,429 c, and 429 d. In the open, ready for packaging configuration, thefront panel 439 and the back panel 429 are attached along three edges(429 a/439 a, 429 b/439 b, and 429 c/439 c), such as via seam adhesivebeing positioned proximate the edges. Notably, in the illustratedembodiment, the fourth edge 439 d of the front panel 439 is not attachedto the back panel 429 (or only attached near the corners) and, instead,an opening 419 to a pocket 415 (shown in FIG. 12B) is formed—allowinginsertion of the item(s) for shipping and delivery.

The dimensions of the padded mailer may vary depending on the desiredapplication. An example padded mailer includes a back panel lengthL_(BP) of ˜20.125 in. and a back panel width W_(BP) of ˜14 in.

Notably, the length L_(BP) of the back panel 429 is greater than thelength L_(FP) of the front panel 349 such that a portion 449 of the backpanel 429 extends above the fourth edge 439 d of the front panel 439.The portion 449 of the back panel 429 can, thus, be used in sealing thepadded mailer 409, such as to seal an item to be shipped and deliveredinside. In this regard, various features for aiding in packaging andopening of the padded mailer can be positioned within the portion 449.For example, FIG. 12A illustrates an example pull-strip 496 forrevealing a strip of adhesive that can be used to attach the portion 449to the front panel 439 once the portion 449 has been folded over tocover the opening 419—thereby transitioning the padded mailer into thesealed configuration. Once the sealed padded mailer has been deliveredto its end destination, a tear strip 497 can be pulled to enable accessto the internal pocket 415 and, thus, the item stored therein.

Notably, embodiments of the present invention contemplate variousfeatures and configurations of a padded mailer that can be utilized.Thus, the illustrated example is not meant to be limiting. For example,in some embodiments, the front panel and the back panel may have similarlengths, the front panel and the back panel may be attached around anitem, and/or other configurations are contemplated. In this regard, asdescribed herein, the padded material can be used in conjunction with apadded mailer formation machine to enclose and form around an item. Oneor more of the above noted features (e.g., pull-strip 496) may beutilized for such a padded mailer that is formed.

With reference to FIG. 12B (which illustrates a cross-sectional view ofthe padded mailer 409 taken along line A-A in FIG. 12A), in theillustrated embodiment, the panels 429, 439 connect along the edges 407to form the pocket 415 for receiving the item 405 to be shipped anddelivered therein. In this regard, in some embodiments a layer of heatseal coating 434 present on the bottom of the second webs 424 of boththe top panel 439 (from a first portion of the padded material 420) andbottom panel 429 (from a second portion of the padded material 420) maybe pressure sealed together (e.g., with heat, for example) along theedges 407 to form the pocket 415 for receiving the item 405.Additionally or alternatively, in some embodiments, the two side edges407 may be adhered together along the length dimension using arecyclable adhesive.

In some embodiments, panels 429, 439 may be formed without the heat sealcoatings 432, 434. In this regard, when the padded mailer 409 utilizes arecyclable adhesive, for a seam adhesive, rather than forming a heatseal between the heat seal coatings 432, 434 the heat seal coatings 432,434 may be redundant and add unnecessary weight to the padded mailer409. Further, as the plurality of starch-based particles 440 adhere towetted surfaces, the plurality of starch-based particles 440 may adhereto the first web 422 and the second web 424 without the heat sealcoating 432, 434 when the padded panels 429, 439 are being adhered to apre-formed padded mailer 409.

In some embodiments, a tear-strip or similar feature may be added to thepadded mailer for ease of opening. However, in some embodiments, toensure that the padding (e.g., starch-based particles) does not escapewhen the tear-strip is removed, the tear-strip may preferably be locatedalong an area of the padded material that does not overlap withstarch-based particles (e.g., within the pattern noted herein). Further,there may be one or more seals on either or both sides of the tear-stripto seal off what will then be an open area (after the tear-strip isremoved).

FIG. 13 shows a schematic representation of another example system forforming a padded mailer from the padded material. The system 600 causesconveyance of first padded material 629, such as from a first roll 628(e.g., using one or more conveyor means, such as a conveyor belt, one ormore rollers, etc., and/or motors), and conveyance of second paddedmaterial 639, such as from a second roll 638 (e.g., using one or moreconveyor means, such as a conveyor belt, one or more rollers, etc.,and/or motors). The first padded material 629 and the second paddedmaterial 639 may be brought together and sealed together, such as duringa seal phase 602. In some embodiments, pressure and/or heat may beapplied to one or more of the edges of the padded material 629, 639 tocause the heat seal coating and/or other adhesive on the padded material629, 639 to adhere together to form the padded mailer. Notably, in someembodiments the interior heat seal coating layer may not be applied forpadded mailers not formed on an automated mailer formation device (asthe interior heat seal coating layer may not be needed).

In some embodiments, a portion of at least one edge of each of thepadded material 629, 639 may not be sealed so as to form an opening ofthe padded mailer. Thereafter, during an apply features phase 604, oneor more features may be applied to the padded mailer, such as atear-strip, adhesive strip, or other feature(s). Finally, during a cutphase 606, the padded mailer to be cut away from the remainder of thepadded material 629, 639—thereby forming the padded mailer 609 that isready to receive the item therein.

Notably, in conjunction with various embodiments described herein,various of the phases can be combined, changed in order of operation,separated, or otherwise changed. In such example embodiments, thecorresponding phases may be adjusted accordingly.

Example Flowchart(s)

Embodiments of the present invention provide methods, apparatuses andcomputer program products for controlling the variouscomponents/features according to various systems described herein.Various examples of the operations performed in accordance withembodiments of the present invention will now be provided with referenceto FIGS. 14-15 .

FIG. 14 illustrates a flowchart according to an example method forforming a padded based material for use in forming a padded mailer. Theoperation illustrated in and described with respect to FIG. 14 may, forexample be performed by, with the assistance of, and/or under thecontrol of the controller 190 and other components/features describedherein, such as in system 100.

The method 700 may include forming a plurality of starch-based particlesat operation 702. At operation 704, the method may comprise applying aheat seal coating to a second surface of a first web. At operation 706,the method may comprise applying a heat seal coating to a second surfaceof a second web. At operation 708, the method may comprise wetting afirst surface of the first web. At operation 710, the method maycomprise applying the plurality of starch-based particles to the wettedsurface of the first web. At operation 712, the method may comprisewetting the heat seal coating material on the second web. At operation714, the method may comprise applying the wetted surface of the secondweb to the plurality of starch-based particles. At operation 716, themethod may comprise forming a padded mailer from the starch-basedmaterial.

FIG. 15 illustrates a flowchart according to an example method forforming a padded material for use in forming a padded mailer. Theoperation illustrated in and described with respect to FIG. 15 may, forexample be performed by, with the assistance of, and/or under thecontrol of the controller 290 and other components/features describedherein, such as in system 200.

The method 800 may include forming a starch-based sheet at operation802. At operation 804, the method may comprise serrating and stretchingthe starch-based sheet. At operation 806, the method may compriseapplying a heat seal coating to a second surface of a first web. Atoperation 808 the method may comprise applying a heat seal coating to asecond surface of a second web. At operation 810, the method maycomprise wetting a first surface of the first web. At operation 812, themethod may comprise applying the starch-based sheet to the wettedsurface of the first web. At operation 814, the method may comprisewetting the heat seal coating material on the second web. At operation816, the method may comprise applying the wetted surface of the secondweb to the starch-based sheet. At operation 818, the method may compriseforming a padded mailer from the starch-based material.

FIGS. 14-15 illustrate flowcharts of various systems, methods, andcomputer program product according to various example embodimentsdescribed herein. Various operations may be performed optionally, andvarious operations may be performed in any order and/or simultaneously.It will be understood that each block of the flowcharts, andcombinations of blocks in the flowcharts, may be implemented by variousmeans, such as hardware and/or a computer program product comprising oneor more computer-readable mediums having computer readable programinstructions stored thereon. For example, one or more of the proceduresdescribed herein may be embodied by computer program instructions of acomputer program product. In this regard, the computer programproduct(s) which embody the procedures described herein may be storedby, for example, the memory and executed by, for example, the controller190, 290. As will be appreciated, any suitable such computer programproduct may be loaded onto a computer or other programmable apparatus,such that the computer program product including the instructions whichexecute on the computer or other programmable apparatus creates meansfor implementing the functions specified in the flowchart block(s).Further, the computer program product may comprise one or morenon-transitory computer-readable mediums on which the computer programinstructions may be stored such that the one or more computer-readablememories can direct a computer or other programmable device to cause aseries of operations to be performed on the computer or otherprogrammable apparatus to produce a computer-implemented process suchthat the instructions which execute on the computer or otherprogrammable apparatus implement the functions specified in theflowchart block(s).

Conclusion

Many modifications and other embodiments of the inventions set forthherein may come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the embodiments of the invention are not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theinvention. Moreover, although the foregoing descriptions and theassociated drawings describe example embodiments in the context ofcertain example combinations of elements and/or functions, it should beappreciated that different combinations of elements and/or functions maybe provided by alternative embodiments without departing from the scopeof the invention. In this regard, for example, different combinations ofelements and/or functions than those explicitly described above are alsocontemplated within the scope of the invention. Although specific termsare employed herein, they are used in a generic and descriptive senseonly and not for purposes of limitation.

1. A packaging material for use in an automated packaging machine, the packaging material comprising: a first web of paper-based material defining a first surface and a second surface opposite the first surface; a first layer of heat seal coating disposed on the second surface of the first web; a second web of paper-based material defining a first surface and a second surface opposite the first surface; a second layer of heat seal coating disposed on the second surface of the second web; and a starch-based padding sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.
 2. The packaging material of claim 1, wherein the starch-based padding covers between about 20% to about 40% of the first surface of the first web.
 3. The packaging material of claim 1, wherein the starch-based padding is precrushed, and wherein the starch-based padding defines a final density between about 1.5 lbs/ft³ to about 2.25 lbs/ft³ after the starch-based padding is precrushed.
 4. The packaging material of claim 1, wherein the starch-based padding comprises lignin.
 5. The packaging material of claim 1, wherein the first surface of the first web is moistened prior to contact with the starch-based padding.
 6. The packaging material of claim 1, wherein the second layer of heat seal coating is moistened prior to contact with the starch-based padding.
 7. The packaging material of claim 1, wherein the starch-based padding comprises starch, a plasticizer, and a foaming aid.
 8. The packaging material of claim 1, wherein the starch-based padding is a plurality of starch-based particles.
 9. The packaging material of claim 8, wherein each of the plurality of starch-based particles define a particle diameter, wherein the particle diameter is between about 0.2 in to about 0.4 in.
 10. The packaging material of claim 8, wherein each of the plurality of starch-based particles define a particle thickness, and wherein the particle thickness is between about in to about 0.25 in.
 11. The packaging material of claim 1, wherein the starch-based padding is a sheet.
 12. A method of forming a packaging material for use in an automated packaging machine, the method comprising: providing a first web of paper-based material, wherein the first web defines a first surface and a second surface; applying a first layer of heat seal coating to the second surface of the first web; providing a second web of paper-based material, wherein the second web defines a first surface and a second surface; applying a second layer of heat seal coating to the second surface of the second web; applying a starch-based padding onto the first surface of the first web; and causing the first web and the second web to come together such that the starch-based padding is sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.
 13. The method of claim 12, wherein the starch-based padding is a plurality of starch-based particles.
 14. The method of claim 13, further comprising: transferring the plurality of starch-based particles from a hopper to a vacuum wheel, wherein the vacuum wheel comprises a plurality of openings in a determined pattern.
 15. The method claim 14, wherein the plurality of starch-based particles are secured within the plurality of openings via vacuum suction.
 16. A mailer formed from a padded material, the padded material comprising: a first web of paper-based material defining a first surface and a second surface opposite the first surface; a first layer of heat seal coating disposed on the second surface of the first web; a second web of paper-based material defining a first surface and a second surface opposite the first surface; a second layer of heat seal coating disposed on the second surface of the second web; and a starch-based padding sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.
 17. The mailer of claim 16, wherein the starch-based padding covers between about 20% to about 40% of the first surface of the first web.
 18. The mailer of claim 16, wherein the starch-based padding defines a final density between about 1.5 lbs/ft³ to about 2.25 lbs/ft³.
 19. The mailer of claim 16, wherein the starch-based padding comprises lignin.
 20. The mailer of claim 16, wherein the first surface of the first web is moistened prior to contact with the starch-based padding.
 21. The mailer of claim 16, wherein the second layer of heat seal coating is moistened prior to contact with the starch-based padding.
 22. The mailer of claim 16, wherein the starch-based padding comprises starch, a plasticizer, and a foaming aid.
 23. The mailer of claim 16, wherein the starch-based padding is a plurality of starch-based particles.
 24. The mailer of claim 23, wherein each of the plurality of starch-based particles define a particle diameter, wherein the particle diameter is between about 0.2 in to about 0.4 in.
 25. The mailer of claim 23, wherein each of the plurality of starch-based particles define a particle thickness, and wherein the particle thickness is between about 0.1 in to about 0.25 in.
 26. The mailer of claim 16, wherein the starch-based padding is a sheet.
 27. A mailer produced by the process of: providing a first web of paper-based material, wherein the first web defines a first surface and a second surface; applying a first layer of heat seal coating to the second surface of the first web; providing a second web of paper-based material, wherein the second web defines a first surface and a second surface; applying a second layer of heat seal coating to the second surface of the second web; applying a starch-based padding onto the first surface of the first web; and causing the first web and the second web to come together such that the starch-based padding is sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web. 28-34. (canceled) 